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Material Handling Information - Pick Cycle Times Too Long
   
Productivity
Pick Cycle Times Too Long

A mini load buffer delivers items to be picked directly to workers at O.C. Tanner.

Workers at Rohm use RF terminals to pick stock stored in conventional racks.
Problem
  • Workers spend too much time walking and searching for materials.
  • Picking sheets give no direction for efficient picking routes.
  • Workers pick single orders with low efficiency.
  • Materials are scattered throughout warehouse.
  • Locations of entire stock are not tracked; only the first location is tracked with a pointer card pointing to subsequent locations.
  • Workers have to de-trash material in addition to picking it.
  • Incorrect material is picked, which forces incorrect material to be re-stored and a second pick for the correct material.
  • Material is stored/picked in the wrong medium.
Solution
  • Bring materials to the worker for picking using mini load, unit load, or high-speed box buffers, carousels, lifters, or conveyor.
  • Use push-back pallet racks to store larger quantities of high-throughput SKUs.
  • Implement directed picking techniques using technology such as pick-to-light or directed picking through RF terminals.
  • Consider alternative picking methods such as batch and zone picking.
  • Use Warehouse Management Software (WMS) and RF terminals to:
    • Allow workers to simultaneously pick multiple orders.
    • Organize materials into zones with frequently picked materials stored together.
    • Track the location of all stock, allowing workers to find and pick items quickly.
    • Verify correct material is picked.
  • De-trash material as it is stored.
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